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Graco 333024E User's Manual

1. HEF 2 5 MOTOR HEAT TRANS 2 FS NS u 89 Electrical Schematics Enclosure Fan 522 24 757 248735 A rons ER Heleteteteter PS N m 248736 qn E Disconnect N SR s PERI lees x EN CERE 2487 56 MOON 91 9 M 160530 Ho 9 dido d DEO d DO 4 CB B P oun Se CT i Eo E MOTOR A HEAT HEAT TRA NS INCOMING POWER DIAGRAM 200 240 VAC 10 200 240 30 DELTA 350 415 VAC 30 WYE tolololololor sisi rece rens prese rese pres L1 L2 L3 16X050A 90 333024 Electrical Schematics B RTD B HEATER Overtemperature Switchs 24P970 15KW 24T242 10KW To ADM To MCM 5 1 16V515 Transformer Fan U p 4 20 To Heated Hose 248756 DiE ol Hose Transformer 160528 ti22678a AN Locate near TCM 333024 97 Reactor 2 Repair Spare Parts Reference Reactor 2 Repair Spare Parts Reference Recommended Common Spare Parts 106 15C852 E 30 Pump Repair Kit Pump 115 106 15C851
2. 53 Repair Circuit Breaker Module 54 Replace Fluid Inlet Sensor 55 Replace Pressure 55 Iseplace Faris sco voted adea etna iuo n dl 56 Repair Primary Heater 59 Repair Heated 63 Repair Fluid Temperature Sensor 64 Replace Power Supply 67 Replace Surge Protector 67 Replace Advanced Display Module ADM deat ov 67 Replace Motor Control Module 68 Software Update 68 Replace Temperature Control Module Me 68 pcc PER EE 69 Electrical 5 89 Reactor 2 Repair Spare Parts Reference 92 Performance 5 93 Technical Specifications 96 e 98 Graco Extended Warranty for Reactor 2 Components 99 333024 Warnings Warnings The following warnings are for the setup use grounding maintenance and repair of this equipment The exclamation point symbol alerts you to a general warning and the hazard symbol refers to procedure specific risks When
3. CSO2RD CSO2RD CS02RD CSO2RD Gun Part No GCP2R2 GCP2R2 GCP2R2 GCP2R2 GCP2R2 GCP2R2 GCP2R2 GCP2R2 ty 1 ty 5 ty 1 ty 5 ty 1 ty 5 ty 1 ty 5 24K240 scuff guard Qty Qty Qty Qty Qty Qty Qty 24Y240 Xtreme Wrap Heated Whip Hose 246050 246050 246050 246050 10 ft 3 m ewm i Full load amps with all devices operating at x Packages include gun heated hose and maximum capabilities Fuse requirements at whip hose Elite packages also include Graco various flow rates and mix chamber sizes InSite and fluid inlet sensors Low line input voltage will reduce power t Total system watts used by system based on available and heaters will not perform at full maximum heated hose length for each unit capacity 30 2 series 310 ft 94 5 m Voltage Configurations Key maximum heated hose length including whip hose DELTA WYE See Approvals page 11 333024E 9 Models Reactor 2 E XP2 and E XP2 Elite All elite systems include fluid inlet pressure and temperature sensors Graco InSite and Xtreme Wrap 50 ft 15 m head hose For part numbers see Accessories page 11 E XP2 Model E XP2 Elite Model 15 kW 15 kW Proportioner 2 2012 272112 Pressure psi MPa bar Cycle gal liter Configurable Voltage 230 10 230 3 380 23010 230 30 380 3 Y Phase Fusion AP Package 3 AP2112 Gun Part No
4. c 29 gt lt 203 203 e 205 6 ti22580a Torque to 120 ft lbs 163 Nem Torque to 23 ft lbs 31 Nem Torque to 40 ft lbs 54 Nem Apply thermal paste Apply pipe sealant and PTFE tape to all non swiveling threads and threads without o rings Apply lithium grease lubricant to o rings before assembling in block 1 Remove tape from probe tip and Orientate sensor as shown Insert probe until it bottoms on heating element Tighten ferrule on sensor probe one turn past finger tight or 16 ft lbs 21 6 Nem 8 333024 Ref Part Description 24U843 24U842 201 HEATER machined 1 zone 1 a HEATER machined dual zone zo 121309_ FITTING adapter saeorb xo J 4 9 _ zo mHsw FITTING 2 9 _ zo mone ADAPTER 1 O RING packing 208 HEATER immersion 2628 J 4 8 209 err SWITCH over temperare 20 15195 MER immersion heater a 3 FIVTING compression 2 1 __ mz ATO y 2 5 SCREW machine pni SHB 2 20 zu wWrs HoUsNG rupture E 3 Included 24L973 Heater RTD Repair Kit 444543454 333024E Parts 9 Parts Fluid Manifold 24U844 3 406 J3 1 402 405 413 404 402 31 401 gt 411 415 419 413 TOT ti22968a Apply PTFE tape and thread s
5. 272112 ID Parts included Graco Insite Kit 247280 6 333024 5 Parts Proportioner Module 24V150 Module for E 30 24V151 Module for E XP2 Torque to 190 120 in Ibs 21 24 Nem Lubricate threads with ISO oil or grease Assemble pump cylinders flush to one full thread under flush of housing surface Apply grease to all gear teeth proportionally motor pinion and drive housing Torque to 20 30 ft Ibs 27 40 6 Crankshaft must be in line with crankshaft at other end of motor Torque to 70 80 ft lbs 95 108 Dpmempmsms6s xs Flat side faces up 6 333024 Description E 30 E XP2 109 257355 HOUSING bearing HOUSING bearing 106 PUMP displacement PUMP displacement A 1124 15C753 SCREW machine hex wash hd 1 25 in x 5 16 18 115 PUMP displacement PUMP displacement B 116 NUT retaining NUT retaining NO 1264 Parts A Replacement Warning labels signs tags and Gear Repair Kit includes washers 107 and cards are available at no cost 108 See pump repair manual 309577 for repair kits Drive Housing Repair Kit includes housing 1 Spring 110 included in Connecting Rod Kit screws 5 and washer 1 to replace one ena 241279 333024 Parts Fluid Heater 24U843 10kW 2 zone 24U842 7 5 kW 1 zone A 212 6 p 213 209 4 206 204 NN B gt
6. Replace Pressure Transducers 1 2 3 Perform Shutdown page 43 Perform Pressure Relief Procedure page 42 Disconnect transducer cables 405 from 6 and 7 connectors on the MCM Remove wire ties constraining transducer cable and remove cable from cabinet Install o ring 416 on new transducer 405 Install transducer in manifold Mark end of cable with tape red transducer A blue transducer B Route new cable into cabinet and thread into bundle as before Attach cable ties to bundle as before Connect A side pressure transducer cable to MCM port 6 Connect B side pressure transducer cable to MCM port 7 22 Repair Replace Fans Shutdown system to avoid electric shock To avoid burns do not perform maintenance on the fan until the system has reached ambient temperature Replace Motor Fan 1 Perform Shutdown page 43 2 Open cabinet door and disconnect fan cables from terminal blocks See Electrical Schematics page 89 4 4 4 00 7 CE WE N ex re FE or E C 77 P akan S Y 3 Remove four screws 21 from motor cover 11 If necessary fold frame 1 to remove motor cover 10 See Repair Drive Housing page 50 steps 1 10 4 Cuttie wraps to remove cable Remove nuts 39 screws 22 washers 34 and fan 32 Install new fan in reverse order Note ti22775
7. Chemical Hose Chemical green connector There should be continuity 70 F If there is no continuity check transformer Current B Current Hose Current c Reconnect pin green connector to TCM PCB 2 Check transformer r F Pressure A Pressure B Hose Voltage a Remove lower shroud ps psi b Locate the two larger 6 AWG wires MEM Bus Total Cycles 400 0 labeled 3 4 coming out of transformer Trace these wires back to TB17 and TB18 Open circuit breaker to turn the color 333024 65 Repair Replace Transformer Perform Shutdown page 43 Remove four bolts 23 and shroud 10 Remove lower dinrail cover 48 Te gt Disconnect fan and transformer connections from terminal blocks Connections are on left side labeled 1 2 3 and 4 5 Remove four nuts 27 holding metal transformer cover 8 to frame Carefully remove cover while sliding wires through hole in cover 6 Remove nuts 27 and transformer 17 7 Install transformer 17 in reverse order ti22871a Figure 18 66 333024 Repair Replace Power Supply 1 Perform Shutdown page 43 2 Disconnect input and output cables from both sides of the power supply See Electrical Schematics page 89 3 Insert a flat head screw driver in the mounting tab on the bottom of the power supply to remove ti2
8. 246101 246101 Probler P2 Package 3 P22112 Gun Part No GCP2R1 GCP2R1 50 ft 15 m scuff guard Xtreme Wrap 10 ft 3 m Graco Sie Fluid Inlet Sensors 2 Full load amps with all devices operating at Packages include gun heated hose and maximum capabilities Fuse requirements whip hose Elite packages also include at various flow rates and mix chamber sizes Graco InSite and fluid inlet sensors Ud Low line input voltage will reduce power t Total system watts used by system based on available and heaters will not perform at full maximum heated hose length for each unit capacity 30 and E XP2 series 310 ft 94 5 m Voltage Configurations Key maximum heated hose length including whip hose Approvals page 11 WYE 2 DELTA 70 333024 Approvals Approvals Accessories Intertek approvals apply to proportioners without hoses Air Manifold Kit 4 outlets Proportioner Approvals 24U314 16X521 Graco InSite Extension cable 24 6 ft 7 5 m 24N449 50 ft 15 m CAN cable for remote display module 24K207 Fluid Temperature Sensor FTS with RTD LISTEN Intertek 9902471 Conforms to ANSI UL Std 499 24U174 Remote Display Module Kit 24K337 Light Tower Kit Certified to CAN CSA Std C22 2 No 88 15V551 ADM Protective Covers 10 pack 15M483 Remote Display Module Protective C Covers 10 pack Note 24M174 Drum Level Sticks Heated hoses provided
9. Repair Parts gt Reactor 2 E 30 and E XP2 Proportioning System 335024 Electric Heated Plural Component Proportioning System For spraying polyurethane foam and polyurea coatings For professional use only Not approved for use in explosive atmospheres or hazardous locations Important Safety Instructions Read all warnings and instructions in this manual Save these instructions 95 Ac PROVEN QUALITY LEADING TECHNOLOGY Contents VIE dare Important Isocyanate Information 7 WOO CIS once sha 9 11 ACCESSOS niche a 11 Supplied Manuals 12 Related Manuals 12 2 13 Troubleshoot Errors 13 Pressure Relief Procedure 42 d mr woul eine tected 43 mi ise MT T HERE 45 PRED all E 46 Before Beginning 46 Flush Inlet Strainer Screen 46 Change Pump Lubricant 47 Remove PUMP lados ue beet 48 PUMP eee 49 Repair Drive HOUSING 50 Repair Electric Motor
10. Troubleshoot Errors There are three types of errors that can occur Errors are indicated on the display as well as by the light tower optional Alarms A parameter critical to the process has reached a level requiring the system to stop The alarm needs to be addressed immediately Deviations A parameter critical to the process has reached a level requiring attention but not sufficient enough to stop the system at this time A parameter that is not immediately critical to the process The advisory needs attention to prevent more serious issues in the future im See Error Codes page 14 for causes and solutions to each error code To troubleshoot the error 333024 Troubleshooting 1 Press the soft key for help with the active error 06 3011 301 Active P iBK R 224 Press 7 224 Press Help With This Note Press Or 3 to return to the previously displayed screen 2 he QR code screen will be displayed Scan the QR code with your smartphone to be sent directly to online troubleshooting for the active error code Otherwise manually navigate to http nelp graco com and search for the active error Troubleshooting E 30 Active C Active Errors E22 Press Sens Err B Job Data Error Code PEE help graco cam 3 If no internet connection is available see Error Codes page 14 for causes and solutions for each
11. LABEL safety multi Parts Qty 63 Parts System DIN Rail and Harness Module Kit 24U850 System DIN Rail and Harness Module Kit Electrical Schematics page 89 10x N 5 eje eje e oO H HHHH HHHHHHH HHH HHH H F H Li LI 4 CO1 505 AN Torque to 6 8 in Ibs 0 7 1 Nem o Torque to 28 33 in Ibs 3 3 8 Nem 3 Torque to 23 26 in Ibs 2 6 3 Nem 333024 4 Ref 501 502 503 16U529 16V515 16U522 Description Qty Ref Part HARNESS breaker 504 16U526 module 1 HARNESS hose out 1 MODULE din rail term blk power sup see System Circuit Breaker 505 160530 Module page 86 1 Heater and Transformer Terminal Block Module 24U849 Ref Part 511 24T315 512 126811 513 126383 514 126382 333024 511 513 515 517 22777 SSS E 3 SS 4 512 514 516 512 Description Qty Ref Part RAIL DIN 35 mm x 7 5 1 5
12. Tighten locknut G by hitting firmly with a non sparking hammer Reconnect fluid inlet C and outlet D Go to step 13 Note Steps 6 12 apply to pump only Ensure star shaped locknut G is screwed on pump with flat side up Carefully twist and extend displacement rod 2 in 51 mm above wet cup 49 Repair gt 5 NEY mL 5 1 16 in 7 Start threading pump into bearing housing When pin holes align insert pin Pull retaining wire clip down 8 Continue threading pump into bearing housing M until top threads are 1 16 in 2 of bearing face N Ensure that barbed fittings at wet cup flush ports are accessible 9 Connect component A outlet tube loosely at pump and at heater Line up tube then tighten fittings securely 10 Tighten star shaped locknut C by hitting firmly with a non sparking hammer 20 11 Apply thin film of TSL to barbed fittings Using two hands support tubes T while pushing straight onto barbed fittings Secure each tube with a wire tie between two barbs Note Do not let tubes kink or buckle 12 Reconnect fluid inlet C 13 Purge air and prime the system See Reactor operation manual Repair Drive Housing Removal 1 Press to stop the pumps 2 Turn off heat zones 3 Flush pump 4 Press to park the pumps in the down position Press to deactivate the system Turn main power switch
13. branding e xp2 elite 333024 3 Parts 160530 MODULE system surge _ 7 protector a 60765 COVER cono 3 60 LN 62 16 5 dor 2 2 2 2 2 2 240832 MODULENCM NO 1 1 1 1 114225 TRIM p protection 1 1 6 ft 0 48 m 127296 SCREW mchn pnh 4 4 4 4 4 4 w ext tooth wash M4 x 0 7 16X129 SCREW mach phillips tooth wash 5 16 x 8 32 117502 FITTING reducer 5 x 8 JIC 117677 FITTING reducer 6 x 10 299521 CAP 1 2 20 cap aluminum 299520 CAP 9 16 18 JIC 1 1 1 1 1 cap aluminum 15V551 SHIELD membrane 1 1 1 1 1 1 ADM 10 pack 24K409 BAR 55 gal chem measure A side 24 411 55 gal chem measure B side 2 5 16W96 7 FITTING swivel 3 4 x 1 npsm 118459 FITTING union swivel 3 4 in 4 333024 Parts Ref Part Description Quantity 1 LABEL branding reactor 2 2 2 2 920 15D906 SUPPRESSOR round 1 1 1 1 1 snap ferrite 260 c pum eben 96 333091 MANUAL quick guide 1 1 1 1 1 startup 333092 MANUAL quick guide 1 1 1 1 1 shutdown A Replacement Warning labels signs tags and See Electrical Schematics page 89 cards are available at no cost Not available for purchase Not shown
14. manufacturer 333024E 3 Warnings SKIN INJECTION HAZARD High pressure fluid from gun hose leaks or ruptured components will pierce skin This may look like just a cut but it is a serious injury that can result in amputation Get immediate surgical treatment Do not spray without tip guard and trigger guard installed Engage trigger lock when not spraying Do not point gun at anyone or at any part of the body Do not put your hand over the spray tip Do not stop or deflect leaks with your hand body glove or rag Follow the Pressure Relief Procedure when you stop spraying and before cleaning checking or servicing equipment Tighten all fluid connections before operating the equipment Check hoses and couplings daily Replace worn or damaged parts immediately FIRE AND EXPLOSION HAZARD Flammable fumes such as solvent and paint fumes in work area can ignite or explode To help prevent fire and explosion Use equipment only in well ventilated area Eliminate all ignition sources such as pilot lights cigarettes portable electric lamps and plastic drop cloths potential static arc Keep work area free of debris including solvent rags and gasoline Do not plug or unplug power cords or turn power or light switches on or off when flammable fumes are present Ground all equipment in the work area See Grounding instructions Use only grounded hoses Hold gun firmly to side of grounded pail when triggering
15. ring B in place and tighten Do not overtighten Let the gasket make the seal Open the fluid inlet valve ensure that there are no leaks and wipe the equipment clean Proceed with operation ti21650a Figure 1 333024 Change Pump Lubricant Check the condition of the ISO pump lubricant daily Change the lubricant if it becomes a gel its color darkens or it becomes diluted with isocyanate Gel formation is due to moisture absorption by the pump lubricant The interval between changes depends on the environment in which the equipment is operating The pump lubrication system minimizes exposure to moisture but some contamination is still possible Lubricant discoloration is due to continual seepage of small amounts of isocyanate past the pump packings during operation If the packings are operating properly lubricant replacement due to discoloration should not be necessary more often than every 3 or 4 weeks To change pump lubricant 1 Follow Pressure Relief Procedure page 42 2 Liftthe lubricant reservoir R out of the bracket and remove the container from the cap Holding the cap over a suitable container remove the check valve and allow the lubricant to drain Reattach the check valve to the inlet hose 3 Drain the reservoir and flush it with clean lubricant 333024E e Repair When the reservoir is flushed clean fill with fresh lubricant Thread the reservoir onto the cap assembly an
16. 515155 EET lt Hem 462 463 HERE Pelco ele ojo O e o o 9 ti22582c i 2 d 466 333024 Electrical Enclosure Ref 451 453 454 455 457 458 459 460 461 462 463 464 466 Part 24U087 24U855 240848 24R736 117666 120859 120858 123967 115942 103181 124131 194337 113505 Description Qty ENCLOSURE 1 MODULE TCM 1 FAN cooling 80 mm 24VDC 1 SWITCH disconnect door mounted 1 TERMINAL ground 1 NUT strain relief 40 thread 1 BUSHING strain relief 40 thread 1 KNOB operator disconnect 1 NUT hex flange head 5 WASHER lock external 2 SCREW machine pan head 5 16 in x 6 32 2 WIRE grounding door 1 NUT keps hex head 6 A Replacement Warning labels signs tags and 333024 cards are available at no cost See Electrical Schematics page 80 Ref 468 469 470 471 472 473 474 475 476 477 478 479 111218 114269 127282 127278 16W925 16W926 24R735 127068 24U850 127290 16X050 16X049 Description CAP tube square GROMMET rubber GROMMET rubber NUT keps hex GASKET enclosure foam GASKET enclosure foam CABLE CAN power M12 female pigtail CABLE CAN female female 1 0 meter MODULE breaker CABLE 4 pin male female 1 3 meter molded hose RTD LABEL safety enclosure
17. Level A Low Chemical Level B Maintenance Due USB Pressure Imbalance A High Low material level Low material level USB logs have reached a level where data loss will occur if logs are not downloaded Pressure difference between A and B material is greater than the defined value Pressure imbalance is defined too low Out of material Fluid leaking from heater inlet rupture disk Feed system defective Refill material and update drum level on ADM Maintenance screen Alarm can be disabled on the System Setup screen Refill material and update drum level on ADM Maintenance screen Alarm can be disabled on the System Setup screen Insert a USB drive into the ADM and download all logs Ensure material flow is equally restricted on both material lines Ensure that the pressure imbalance value on the oystem Setup screen is at an acceptable maximum pressure to prevent unnecessary alarms and abort dispenses Fill tanks with material Check if heater and PRESSURE RELIEF SPRAY valve are plugged Clear Replace rupture disk Do not replace with a pipe plug Check feed pump and hoses for blockage Check that feed pumps have correct air pressure 79 Troubleshooting 20 Pressure Imbalance B High Low Inlet Pressure A Low Inlet Pressure B Low Inlet Pressure A Pressure Ensure material flow is difference between equally restricted on both A and B material
18. Module TCM Perform Shutdown page 43 Open electrical enclosure door 61 Disconnect all connectors from the TCM 453 Remove four nuts 461 and TCM 453 Install new TCM module 453 Reassemble parts in reverse order pL e gt I I e C 8 16 e Figure 23 Replace TCM 333024 Parts Parts Proportioners 26 38 WE 1225766 23 33 23 67 48 69 333024 Parts gt gt 70 Apply anaerobic polyacrylate pipe sealant to all non swiveling pipe threads Apply grease to tube fitting threads Torque to 43 ft lbs 58 Nem Safety and warning labels are from label sheet 68 ti22577a 333024 Parts Ref Part Description Quantity pop ENCLOSURE electrical see Electrical Enclosure page 82 246995 BOTTLE assembly complete 16X531 BRACKET tsl bottle 24U843 HEATER 10kw 2 zone RTD see Fluid Heater page 78 24U842 HEATER 7 5kw 1 zone RTD see Fluid Heater page 78 24U704 MANIFOLD fluid see 1 1 1 1 1 1 Fluid Manifold page 80 7 16W654 INSULATOR foam 2 4 4 2 4 4 heater 261821 CONNECTOR wire 6awg mum cover rear ___ a _ 3 t wes cover mo 3 3 a Lo 2 oover eser 1 1 1 cues vsa
19. VAC High Voltage CAN Bad 24 VDC power Check voltage of power supply supply Voltage should be 23 25 VDC If out of tolerance replace power supply High Voltage A Incoming line Ensure incoming system voltage is too high power is wired properly Verify voltage at each circuit breaker is between 195 and 264 VAC 333024 Error V3MB V3MH V4CM VAIT VAMA VAMB V4MH 333024 B B B B B E Ji Troubleshooting High Voltage B High Voltage Hose High Voltage MCM High Voltage CAN High Voltage A High Voltage B High Voltage Hose Incoming line voltage is too high Incoming line voltage is too high Incoming line voltage is too high Bad 24 VDC power supply Incoming line voltage is too high Incoming line voltage is too high Incoming line voltage is too high Ensure incoming system power is wired properly Verify voltage at each circuit breaker is between 195 and 264 VAC Ensure incoming system power is wired properly Verify voltage at each circuit breaker is between 195 and 264 VAC Ensure incoming system power is wired properly Verify voltage at each circuit breaker is between 195 and 264 VAC Check voltage of power supply Voltage should be 23 25 VDC If out of tolerance replace power supply Ensure incoming system power is wired properly Verify voltage at each circuit bre
20. and approximately 1 4 turn wide Apply thermal paste to the stem of dial before assembling into housing 333024 Parts 87 Parts Ref Part Description Quantity 24U320 24U321 TRANSDUCER pressure temperature includes foam EM Optional 80 mesh filter 255082 2 pack Included in 24V020 Inlet Filler and Seal Kit 20 mesh 2 pack ncluded 247503 Manifold Repair Kit NO 68 333024E Electrical Schematics Rotary Switch Positions Reactor 2 E 30 Reactor 2 E XP2 To TCM 127068 5 T unused unused unused E gt REACTOR 2 gt gt Motor Temperature L1 MotorPower ti22679a 333024 Electrical Schematics 24R735 To Power Supply B Pressure Transducer Pressure Transduce Fluid Manifold Inlet Pressure Temperature Transducer B Inlet Pressure Temperature Transducer me unused y gt AR EDN r AN EL 24 Ws REACTOR 2 24U831 1 oN lt J 240832 A PIK AL intet us M A Inlet 241050 117666 LALONG _________
21. area Material Self Ignition some materials may become self igniting if applied too thick Read material manufacturer s warnings and material MSDS 333024 Keep Components and Separate Cross contamination can result in cured material in fluid lines which could cause serious injury or damage equipment To prevent cross contamination Never interchange component A and component B wetted parts Never use solvent on one side if it has been contaminated from the other side Moisture Sensitivity of Isocyanates Exposure to moisture such as humidity will cause ISO to partially cure forming small hard abrasive crystals which become suspended in the fluid Eventually a film will form on the surface and the ISO will begin to gel increasing in viscosity NOTICE Partially cured ISO will reduce performance and the life of all wetted parts Always use a sealed container with a desiccant dryer in the vent or a nitrogen atmosphere Never store 150 an open container Keep the ISO pump wet cup or reservoir if installed filled with appropriate lubricant The lubricant creates a barrier between the 150 and the atmosphere Use only moisture proof hoses compatible with ISO Never use reclaimed solvents which may contain moisture Always keep solvent containers closed when not in use Always lubricate threaded parts with an appropriate lubricant when reassembling Important Isocyanat
22. area Comply with all applicable safety regulations Warnings MOVING PARTS HAZARD Moving parts can pinch cut or amputate fingers and other body parts Keep clear of moving parts Do not operate equipment with protective guards or covers removed Pressurized equipment can start without warning Before checking moving or servicing equipment follow the Pressure Relief Procedure and disconnect all power sources BURN HAZARD Equipment surfaces and fluid that is heated can become very hot during operation To avoid severe burns Do not touch hot fluid or equipment 6 333024 Important Isocyanate Information Important Isocyanate Information Isocyanates ISO are catalysts used in two component materials Isocyanate Conditions opraying or dispensing materials containing isocyanates creates potentially harmful mists vapors and atomized particulates Read material manufacturer s warnings and material MSDS to know specific hazards and precautions related to isocyanates Prevent inhalation of isocyanate mists vapors and atomized particulates by providing sufficient ventilation in the work area If sufficient ventilation is not available a supplied air respirator is required for everyone in the work area To prevent contact with isocyanates appropriate personal protective equipment including chemically impermeable gloves boots aprons and goggles is also required for everyone in the work
23. installed inlet sensors should be disabled on the oystem Setup screen Check to ensure inlet sensor is properly installed and all wires are properly connected Check if the error follows the inlet sensor Disconnect inlet sensor cables from the MCM connectors 8 and 9 Reverse A and B connections and check if the errors follows If the error follows the sensor replace the inlet sensor Ensure material flow is equally restricted on both material lines Ensure that the pressure imbalance value on the oystem Setup screen is at an acceptable maximum pressure to prevent unnecessary alarms and abort dispenses Fill tanks with material Check if heater and PRESSURE RELIEF SPRAY valve are plugged Clear Replace rupture disk Do not replace with a pipe plug Check feed pump and hoses for blockage Check that feed pumps have correct air pressure 23 Troubleshooting 24 Pressure Imbalance B High Low Temperature A Pressure Ensure material flow is difference between equally restricted on both A and B material material lines is greater than the defined value Pressure imbalance is defined too low Ensure that the pressure imbalance value on the oystem Setup screen is at an acceptable maximum pressure to prevent unnecessary alarms and abort dispenses Out of material Fill tanks with material Fluid leaking from Check if heater heater inlet rupture and PRESSURE disk RELIEF SP
24. is low loosen ferrule nut N and tighten RTD housing H to ensure RTD tip contacts element 212 when ferrule nut N is retightened 212 206 208 201 209 lp _____ 5N A 213 210 T 7 IT lt lt He LA 4 ES Figure 14 62 LO ti22870a 333024 Repair Heated Hose Refer to the heated hose manual 309572 for hose replacement parts Check Hose Heat Connectors 1 Perform Shutdown page 43 Note Whip hose must be connected 2 Disconnect hose connector V at Reactor see Fig 13 3 Using an ohmmeter check between the connectors V There should be continuity 4 If hose fails test retest at each length of hose including whip hose until failure is isolated Check RTD Cables and FTS Perform Shutdown page 43 Disconnect RTD cable C at Reactor Test with an ohmmeter between pins of cable connector C Note Do not touch outer ring with test probe 2 6 5 4 EA 1 a 3 119032 ms _ 3 to 1 approximately 1090 ohms 3 to 4 approximately 1090 ohms 2 to any infinity open 4 Retest at each length of hose including whip hose until failure is located 333024 Repair If the FTS is not reading properly at the end of the hose connect FTS directly to RTD cable C at the manifold If the FTS reads properly at the manifold but not at the end of the hose check
25. material lines is greater than the defined value Pressure Ensure that the pressure imbalance is imbalance value on the defined too low oystem Setup screen is at an acceptable maximum pressure to prevent unnecessary alarms and abort dispenses Out of material Fill tanks with material Fluid leaking from Check if heater heater inlet rupture and PRESSURE disk RELIEF SPRAY valve are plugged Clear Replace rupture disk Do not replace with a pipe plug Feed system Check feed pump and defective hoses for blockage Check that feed pumps have correct air pressure Inlet pressure Ensure that inlet pressure lower than defined to the pump is sufficient value Value defined too Ensure that the low high pressure alarm level defined on the System oetup screen is acceptable Inlet pressure Ensure that inlet pressure lower than defined to the pump is sufficient value Value defined too Ensure that the low high pressure alarm level defined on the System oetup screen is acceptable Inlet pressure Ensure that inlet pressure lower than defined to the pump is sufficient value Value defined too Ensure that the low high pressure alarm level defined on the System oetup screen is acceptable 333024 333024 Low Inlet Pressure B High Pressure A High Pressure B Inlet pressure lower than defined value Value defined too high oystem pressurized before allowing heat to re
26. these symbols appear in the body of this manual refer back to these Warnings Product specific hazard symbols and warnings not covered in this section may appear throughout the body of this manual where applicable ELECTRIC SHOCK HAZARD This equipment must be grounded Improper grounding setup or usage of the system can cause electric shock Turn off and disconnect power at main switch before disconnecting any cables and before servicing or installing equipment Connect only to grounded power source All electrical wiring must be done by a qualified electrician and comply with all local codes and regulations Do not expose to rain Store indoors TOXIC FLUID OR FUMES Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin inhaled or swallowed Read MSDSs to know the specific hazards of the fluids you are using e Store hazardous fluid in approved containers and dispose of it according to applicable guidelines Always wear chemically impermeable gloves when spraying dispensing or cleaning equipment PERSONAL PROTECTIVE EQUIPMENT Wear appropriate protective equipment when in the work area to help prevent serious injury including eye injury hearing loss inhalation of toxic fumes and burns This protective equipment includes but is not limited to Protective eyewear and hearing protection Respirators protective clothing and gloves as recommended by the fluid and solvent
27. 15 120570 mm x 7 in 516 249758 BLOCK clamp end 2 COVER end 1 517 24R759 BLOCK terminal 2 Description MODULE din rail circuit breakers see Power Supply and Terminal Block Module page 86 MODULE sys surge protector Description BLOCK terminal BLOCK terminal UT 2 5 red BLOCK terminal UT 2 5 black Parts Qty Qty 65 Parts System Circuit Breaker Module 16U526 523 524 522 Ref Part Description Qty Ref Part 521 514014 RAIL DIN 35 mm x 1 524 17A314 7 5 mm x 8 625 in 522 120838 TERMINAL end stop 2 525 17A317 523 17A319 CIRCUIT breaker 1 1 pole 50A C Curve Power Supply and Terminal Block Module 16U522 931 534 535 532 532 99 eeoooo p BER LL UD LAID LAID s 532 533 536 ti22779a Ref Part Description Qty Ref Part 531 514014 RAIL DIN 35 mm x 7 5 1 534 248723 mm x 8 625 in 532 120838 TERMINAL end stop 3 535 126453 533 24R722 BLOCK terminal PE 1 536 24R724 quad ABB 86 Description Qty CIRCUIT breaker 2P 1 20A 01489 CIRCUIT breaker 2 3 40A 01489 Description Qty BLOCK terminal quad 2 M4 ABB POWER SUPPLY 24V 1 BLOCK terminal UT35 6 333024 Fluid Inlet Kits 24U320 Standard 240321 Elite ti22738b PAS Apply sealant to all tapered pipe threads Apply sealant to female threads Apply to at least the first four threads
28. 2762 from the din rail Figure 20 Surge Protector 4 Install new power supply 535 in reverse order Replace Advanced Display Module ADM 1 Loosen four screws 70 on inside of electrical enclosure door 61 Lift up and pull out to remove ADM 88 2 Disconnect CAN cable 475 3 Inspect ADM 88 for damage Replace if necessary ti22763a Q ti22761a Figure 19 24 VDC Power Supply Replace Surge Protector 1 Loosen connections on terminals 1 and 3 on 2 2 Loosen connections on input to power supply 535 on N and L connections 3 Remove two screws 413 and surge protector 505 from enclosure Figure 21 4 Install new surge protector 505 in reverse order Note Wire on both the circuit breaker and power supply are interchangeable 333024 67 Repair Replace Motor Control Module MCM 1 Perform Shutdown page 43 2 Disconnect connectors from MCM 63 Disconnect two power cables See Electrical Schematics page 89 Remove nuts 91 63 oet rotary switch 2 E 30 and 3 2 Replace MCM in enclosure Connect cables to MCM See Electrical Schematics page 89 Ye a Figure 22 Replace MCM Software Update Procedure NOTICE Repair kit GCA modules are shipped pre programmed and software loading is not necessary software version upgrade 15 necessary follow the procedure in the manual provided 68 Replace Temperature Control
29. 3 port 15 on the MCM Remove connector by loosening four terminal screws 4 4 Remove motor shroud 11 Rest the motor shroud assembly behind the motor without straining the fan power cable 5 Disconnect over temperature cable from port 2 on MCM Cut tie wraps around harness to remove cable 6 Remove four screws 25 holding motor 101 to bracket Lift motor off unit 333024 Repair 101 ti22824a Installation Place motor on unit Thread motor cables into conduit as before See Electrical Schematics page 89 Fasten motor with screws 25 until screws are fully threaded in frame Do not tighten screws until drive housing and pumps are connected to the motor Install drive housing and pump assemblies see Installation page 52 Route motor 101 power cord from motor through conduit and connect to port 15 on MCM Route over temperature cable up from motor and connect to port 2 on MCM Insert cables in conduit and use tie wraps to secure the conduit together Connect motor shroud assembly to motor 101 Install drive housing covers and motor cover Return to service 23 Repair Repair Circuit Breaker Module wa 1 See Before Beginning Repair page 46 2 Using an ohmmeter check for continuity across circuit breaker top to bottom If no continuity trip breaker reset and retest If still no continuity replace breaker as follows a 24 Refer t
30. Allow equipment to cool Problem Reactor ADM does not turn on Electric motor does not operate Tripped circuit breaker CBO2 Reset breaker see Repair Circuit Breaker Module page 54 Check 240VAC at output of breaker Shorted windings Replace motor see Repair Electric Motor page 53 Electric motor runs erratically Failed motor bearing Replace motor see Repair Electric Motor page 53 333024 35 Troubleshooting Cooling fans not working Loose wire Check See Electrical Schematics page 89 Fan blade obstructed Remove obstruction Defective fan Replace See Replace Motor Fan page 56 Pump output low Obstructed fluid hose or gun fluid Open clear use hose with larger hose ID too small ID Worn piston valve or intake valve See pump manual in displacement pump Pressure setpoint too high Reduce setpoint and output will increase Fluid leak in pump packing nut Worn throat seals Replace See pump manual area No pressure on one side Fluid leaking from heater inlet Check if heater and PRESSURE rupture disk 372 RELIEF SPRAY valve SA or SB are plugged Clear Replace rupture disk 372 with a new one do not replace with a pipe plug 36 333024 Troubleshooting Hose Heat System 2 MPa bar PSI es Before performing any troubleshooting procedures 1 Relieve Pressure See Pressure Relief Procedure page 42 2 Turn main power switch OFF 3 Allow equipment to cool H
31. C before using the system Bad electric motor Replace electric motor Check all wiring and connection to RTD Switch the RTD with another and see if the error message follows the RTD Replace RTD if the error follows the RTD 29 Troubleshooting Disconnected or Error T6DB T6DH T6DT r1 a Sensor Error B Sensor Error Hose Sensor Error TCM loose RTD cable or connection Bad RTD Disconnected or shorted RTD cable in hose or bad FTS Shorted RTD cable in hose or FTS Shorted A or B Heater RTD Check all wiring and connection to RTD Switch the RTD with another and see if the error message follows the RTD Replace RTD if the error follows the RTD Expose each hose RTD connection to check and retighten any loose con nector Measure hose RTD cable and FTS continuity oee Repair Heated Hose page 63 Order RTD Test kit 24N365 for measure ment Disconnect hose RTD and use manual hose mode to finish job until repair can be completed Expose each hose RTD connection to check for exposed and shorted RTD wires Measure hose RTD cable and FTS continuity oee Repair Heated Hose page 63 Order RTD Test kit 24N365 for measure ment Disconnect hose RTD and use manual hose mode to finish job until repair can be completed If the error still occurs with the hose FTS unplugged one of the heater RTDs is bad Unplug the A or RTD from the TCM If unplugg
32. E XP2 Pump Repair Kit Pump 115 106 246963 E XP2 Wet Cup Repair Kit Pump 115 106 246964 E 30 Wet Cup Repair Kit Pump 115 606 24 020 Y Strainer Filter and Gasket Kit Y Strainer 607 pack of two each 402 241824 Drain Valve Cartridge Fluid Manifold 403 102814 Fluid Pressure Gauge Fluid Manifold 212 24N450 RTD Cable 50 ft replacement 24N365 RTD Cable Test Kit To assist measureing Hose RTDs and RTD cable resistances 92 333024E Performance Charts Performance Charts Use these charts to help identify the proportioner that will work most efficiently with each mix chamber Flow rates are based on a material viscosity of 60 cps To prevent system damage do not pressurize the system above the line for the gun tip size being used Proportioners For Foam 4242 01 AR5252 02 AR6060 03 PRESSURE psi bar AR7070 04 35 15 9 FLOW Ibs min kg min 333024 93 Performance Charts Proportioners For Coatings Table 1 Fusion Air Purge Round Pattern AR2020 000 PRESSURE AR2929 psi bar 00 4242 01 FLOW gal min l min Table 2 Fusion Air Purge Flat Pattern 3500 241 24 1 3000 207 20 7 2500 AF2929 174 17 4 AF2020 FTXX38 TIP FTXX24 TIP PRESSURE 2006 138 13 8 AF4242 FTXX38 1500 103 10 3 AF5252 1000 48 69 6 9 500 35 3 5 FLOW gal
33. If resistance is not approximately O and switches are 0 Replace cable in place of original cable If switch fails test remove screws Discard failed switch Apply a thin layer of thermal compound 333024 Repair 110009 install new switch in same location on housing 201 and secure with screws 213 Reconnect cables ti22869a 61 Repair Replace RTD 1 Perform Shutdown page 43 2 Wait for heater to cool 3 Remove heater cover 10 4 Cut cable ties around the woven wrap with the RTD cable 212 Disconnect RTD cable 212 from TCM 453 Loosen ferrule nut N Remove RTD 212 from heater housing 201 then remove RTD housing H Do not remove the adapter 206 unless necessary If adapter must be removed ensure that mixer 210 is out of the way when replacing the adapter e 7 Remove RTD cable 212 from woven wrap 8 Replace RTD 212 a Apply PTFE tape and thread sealant to male pipe threads and tighten RTD housing H into adapter 206 b Push in RTD 212 so tip contacts heater element 208 c Holding RTD 212 against heater element tighten ferrule nut N 3 4 turn past finger tight 9 Route wires S as before through woven wrap and reconnect RTD cable 212 to the TCM 10 Replace heater shroud 10 11 Follow startup instructions in the operation manual Turn on A and B heat simultaneously to test Temperatures should rise at same rate If one
34. RAY valve are plugged Clear Replace rupture disk Do not replace with a pipe plug Feed system defective Check feed pump and hoses for blockage Check that feed pumps have correct air pressure Use a smaller mix chamber that is rated for the unit in use If recirculating decrease flow or decrease temperature setpoint Flow is too high at current setpoint Bad RTD or bad RTD placement against heater owap A and B heater output cables and RTD cables and see if issue follows If so replace RTD Confirm resistance of heater Heater resistance should be 9 12 O for 10 kW systems and 6 8 O for 15 kW systems out of tolerance check for loose heater rod wire s wires or replace heater rod if necessary Bad heater rod or loose heater wire 333024 Troubleshooting 333024 Low Temperature B Low Temperature Hose Low Temperature Inlet A Low Temperature Inlet B Flow is too high at current setpoint Bad RTD or bad RTD placement against heater Bad heater rod or loose heater wire Flow is too high at current setpoint Cold chemical in unheated portion of system passed hose FTS at startup Inlet fluid temperature is below the defined level Inlet fluid temperature is below the defined level Use a smaller mix chamber that is rated for the unit in use If recirculating decrease flow or decrease temperature setpoint owap A and B heater outp
35. Requirement Nominal 200 240 VAC 1 Phase 50 60 Hz Nominal 200 240 VAC 3 phase DELTA 50 60 Hz Nominal 350 415 VAC 3 phase WYE 50 60 Hz Heater Power at 230 VAC rated voltage E 30 10 kW 10 200 Watts E 30 15 kW 15 300 Watts E XP2 15 kW 15 300 Watts 195 265 VAC 195 265 VAC 340 455 VAC 96 333024E Technical Specifications Sound Pressure Sound Pressure measured per 150 9674 2 E 30 Measured from 3 1 ft 1 m at 7000 psi 7 MPa 70 bar 3 11 4 87 3 dBA E XP2 Measured from 3 1 ft 1 m at 3000 psi 27 MPa 207 bar 1 3 8 Sound Power E 30 Measured from 3 1 ft 1 m at 7000 psi 7 MPa 70 bar 3 11 4 79 6 dBA 93 7 dBA E XP2 86 6 dBA Measured from 3 1 ft 1 m at 3000 psi 27 MPa 207 bar 1 3 8 lom ROM IS Fluid Inlets Component A ISO and 3 4 NPT f with 3 4 NPSM f union Component B RES 8 1 2 in JIC with 5 5 16 in JIC adapter Component B RES 10 5 8 in JIC with 6 3 8 in JIC adapter Fluid Circulation Ports Size 1 4 NPSM m Maximum Pressure 250 psi 1 75 MPa 17 5 bar Wetted Parts Material Aluminum stainless steel zinc plated carbon steel brass carbide chrome chemically resistant o rings PTFE ultra high molecular weight polyethylene 333024E 97 Notes Notes 98 333024 Graco Extended Warranty for Reactor 2 Components G
36. a Ensure fan 32 blows onto motor Figure 10 56 333024 Replace Electrical Enclosure Fan 1 Perform Shutdown page 43 2 Open electrical enclosure door 401 Loosen four nuts 421 and remove fan 404 3 Install new fan 404 in reverse order of disassembly so that the fan blows out of the electrical enclosure ti22769a Figure 11 333024 Repair 2 Repair 4 Disconnect fan and transformer connections from terminal blocks Connections are on left side labeled V 1 2 3 and 4 5 Remove four nuts 27 holding metal transformer cover 8 to frame Carefully remove cover while sliding wires through hole in cover Replace Transformer Fan n 43 6 Remove four screws 23 washers 29 2 Remove four bolts 23 and shroud 10 32 Remove bolt 20 on top of the heater junction 7 Install fan in reverse order box 48 be 4 ALES by Me e 7 lt UL OA 542505 zn 48 jer 5 4 k 5 0 2 SS 6 Figure 12 28 333024 Repair Repair Primary Heater 8 Wait for heater to cool 9 Remove four bolts 23 and shroud 10 EAD a Replace Heater Element 1 Press to stop the pumps 2 Turn off heat zones GRACO 06 21711 10 43 Recipes ti22867a 3 Flush pu
37. a vise Use a wrench to remove heater element 208 Inspect element It should be relatively smooth and shiny Replace element if there is a crusted Figure 13 60 0 i ce gt a 20 21 22 23 24 25 burnt ash like material adhered to element or sheath shows pitting marks Install new heater element 208 holding mixer 210 so it does not block RTD port Secure heater to frame with bolts 23 Reinstall RTD 212 Repair Primary Heater page 59 Reconnect cable to overtemperature switches 209 Reconnect wires to lower din rail If necessary install lower din rail 33 Install lower din rail cover 48 Line Voltage The heater outputs its rated wattage at 240 VAC Low line voltage will reduce power available and the heater will not perform at full capacity ti22868a 333024 Repair Overtemperature Switch 1 2 3 4 Perform Shutdown page 43 Wait for heaters to cool Remove heater cover 10 Disconnect overtemperature switches 209 from cable 46 Test across spade terminals with ohmmeter a Ifthe resistance is not approximately 0 ohms the overtemperature switch needs to be replaced Go to step 5 b Ifthe resistance is approximately 0 ohms inspect cable 46 to ensure it is not cut or open Reconnect the overtemperature switch 209 and cable 46 Disconnect cable from TCM Test from pin 1 to 3 and 1 to 4
38. a well ventilated area Do not turn on heaters until fluid lines are clear of solvent Flush out old fluid with new fluid or flush out old fluid with a compatible solvent before introducing new fluid Use the lowest possible pressure when flushing All wetted parts are compatible with common solvents Use only moisture free solvents 333024 Flushing To flush feed hoses pumps and heaters separately from heated hoses set PRESSURE RELIEF SPRAY valves SA SB to PRESSURE RELIEF CIRCULATION 9 Flush through bleed lines N GA GB SA 5 Q 0949 n D A j Ww To flush entire system circulate through gun fluid manifold with manifold removed from gun ME 8 To prevent moisture from reacting with isocyanate always leave the system filled with a moisture free plasticizer or oil Do not use water Never leave the system dry See Important Isocyanate Information page 7 45 Repairing this equipment requires access to parts that may cause electric shock or other serious injury if work is not performed properly Be sure to shut off all power to equipment before repairing Before Beginning Repair NOTICE Proper system setup startup and shutdown procedures are critical to electrical equipment reliability The following procedures ensure steady voltage Failure to follow these procedures will cause voltag
39. ach setpoint Bad pressure transducer E XP2 system configured as E 30 oystem pressurized before allowing heat to reach setpoint Bad pressure transducer E XP2 system configured as E 30 Troubleshooting Ensure that inlet pressure to the pump is sufficient Ensure that the low pressure alarm level defined on the System oetup screen is acceptable Pressure in the hose and pumps will increase as the system heats up Turn on heat and allow all zones to reach the temperature setpoint before turning on the pumps Verify the ADM pressure reading and the analog gauges at the manifold Alarm level is lower for E 30 than for E XP2 Ensure dial on MCM is set to position 3 for E XP2 Pressure in the hose and pumps will increase as the system heats up Turn on heat and allow all zones to reach the temperature setpoint before turning on the pumps Verify the ADM pressure reading and the analog guages at the manifold Alarm level is lower for E 30 than for E XP2 Ensure dial on MCM is set to position 3 for E XP2 21 Troubleshooting Pressure Sensor Error A 22 Pressure Sensor Error B Pressure Sensor Error Inlet A connection Bad sensor connection Bad sensor Inlet sensors not installed connection Bad sensor Check to ensure the pressure transducer is properly installed and all wires are properly connect
40. aker is between 195 and 264 VAC Ensure incoming system power is wired properly Verify voltage at each circuit breaker is between 195 and 264 VAC Ensure incoming system power is wired properly Verify voltage at each circuit breaker is between 195 and 264 VAC 33 Troubleshooting WBCO MCM ooftware Version Incorrect software Insert a system token into Error version the ADM module and cycle the power Wait until the upload is complete before removing the token MCM does not If V1CM also exists see have line voltage troubleshooting for V1CM The software version cannot be read if the MCM does not have line voltage WMIO TCM Fan Error Fan inside TCM Check for debris in the TCM is not operating fan and clear with forced air properly if necessary WSUX Configuration Error valid Inset a system token into USB configuration file the ADM and cycle power can t be found for Wait until the lights on the the USB USB port stop flashing before removing token WXUD ADM USB Download Error Log download Backup and reformat the failed USB drive Retry download WXUU ADM USB Upload Error Custom language Perform normal USB file failed to upload download and use the new disptext txt file to upload the custom language 34 333024 Troubleshooting Before performing any troubleshooting procedures 1 Relieve Pressure See Pressure Relief Procedure page 42 2 Turn main power switch OFF 3
41. al Data in this and all other equipment instruction manuals Read fluid and solvent manufacturer s MSDSs and recommendations EQUIPMENT MISUSE HAZARD Misuse can cause death or serious injury Do not operate the unit when fatigued or under the influence of drugs or alcohol Do not exceed the maximum working pressure or temperature rating of the lowest rated system component See Technical Data in all equipment manuals Use fluids and solvents that are compatible with equipment wetted parts See Technical Data in all equipment manuals Read fluid and solvent manufacturer s warnings For complete information about your material request MSDS from distributor or retailer Do not leave the work area while equipment is energized or under pressure Turn off all equipment and follow the Pressure Relief Procedure when equipment is not in use Check equipment daily Repair or replace worn or damaged parts immediately with genuine manufacturer s replacement parts only Do not alter or modify equipment Alterations or modifications may void agency approvals and create safety hazards Make sure all equipment is rated and approved for the environment in which you are using it Use equipment only for its intended purpose Call your distributor for information Route hoses and cables away from traffic areas sharp edges moving parts and hot surfaces Do not kink or over bend hoses or use hoses to pull equipment Keep children and animals away from work
42. before removing the token Dial set to wrong Ensure the MCM dial is set position to the correct position 2 for E 30 3 for E XP2 No 24 VDC supply Green light on each module to module should be lit If green light is not lit check to make sure each CAN cable connection is tight Verify the power supply is outputting 24 VDC If not check power supply wiring If wiring is okay replace the power supply Loose or broken Check the CAN cables CAN cable running between GCA modules and tighten of needed If the problem still persists move each cable around the connector and watch the flashing yellow light on the GCA modules If the yellow light stops flashing replace the CAN cable Heater B No Current B Tripped circuit Visually check circuit breaker breaker for a tripped condition Loose broken Check heater wiring for connection loose wires condition n 333024 Error CACT DADX DEOX 333024 Troubleshooting TCM Pump Runaway Cycle Switch Error have software to module Loose or broken CAN cable Flow rate is too large Faulty or missing cycle switch Missing or out of place cycle switch magnet No 24 VDC supply Green light on each module Inlet ball valves are closed Open ball valves Insert a system token into the ADM module and cycle the power Wait until the upload is complete before removing the token should be lit If green light is not lit check to make s
43. cable C connections Verify they are tight FM Heated Hose Figure 15 Note To assist in taking readings order RTD Test Kit 24N365 Kit includes two cables one cable with a compatible female M8 connector and another cable with a male M8 connector Both cables have stripped wire at the other end for easy test probe access to 1 brown to approximately 1090 ohms 110 4 brown to black 0 2 0 4 ohms 2 to any N A infinity open to 4 blue to black approximately 1090 ohms 63 Repair Repair Fluid Temperature Sensor FTS Installation The Fluid Temperature Sensor FTS is supplied with the system Install FTS between main hose and whip hose See Heated Hose manual 309572 for instructions W ti18511a Figure 16 a Disconnect air hoses C L and electrical connectors D Test Removal D b Disconnect FTS from whip hose W and 1 Perform Shutdown page 43 fluid hoses A B 2 Remove tape and protective covering from FTS c Remove ground wire K from ground screw Disconnect hose cable F on underside of FTS 3 IfFTS is not reading properly at the end of the d Remove FTS probe H from component A hose see Check RTD Cables and FTS page 63 ISO side of hose 4 If FTS fails replace FTS 64 333024 Repair Transformer Primary Check indicator on the circuit breaker GREEN Use an ohmmeter to test for continuity between See Electrical Schematics page 89 two
44. ce For patent information see www graco com patents Original Instructions This manual contains English MM 333024 Graco Headquarters Minneapolis International Offices Belgium China Japan Korea GRACO INC AND SUBSIDIARIES P O BOX 1441 MINNEAPOLIS MN 55440 1441 USA Copyright 2014 Graco Inc All Graco manufacturing locations are registered to ISO 9001 WWW graco com Revision E February 2015
45. d place it in the bracket The lubrication system is ready for operation No priming is required ti20579a 4 Pump Lubrication System Figure 2 4 Repair Remove Pump gt gt MA Pr Y z 7 mG Pump rod and connecting rod move during operation Moving parts can cause serious injury such as pinching or amputation Keep hands and fingers away from connecting rod during operation Y mA 7 X ANS Nan e Note See manual 309577 for pump repair instructions Press to stop the pumps Turn off heat zones 8 Route fluid to waste containers or supply tanks 3 Flush pump Turn PRESSURE RELIEF SPRAY valves SA SB to PRESSURE RELIEF CIRCULATION 4 Press to park the pumps in the down position 5 Press to deactivate the system lt Ensure gauges drop to 0 Turn main power switch off GA GB S i amp ds 3 7 Shut off both feed pumps Close all fluid supply valves 48 333024 Note Use drop cloth or rags to protect Reactor and surrounding areas from spills Note oteps 9 11 apply to pump A To disconnect pump B go to steps 12 and 13 Disconnect fittings at fluid inlet C and outlet D Also disconnect steel outlet tube from heater inlet D
46. e 74 333024 Troubleshooting motor wiring to ensure no bare wires are touching and that no wires are shorted to ground Motor will not Remove pump gear rotate housings from motor and check that motor shaft rotates freely in direction indicated on motor housing Damaged gear Check pump gear trains train for damage and repair or AANM High Motor Current Short circuit of Check wiring to the motor replace as necessary Chemical pump is Repair or replace chemical stuck pump ATDA Heater A Unexpected Current Shorted If error cannot be cleared A or regenerates consistently replace module ATDB Heater B Unexpected Current Shorted TCM If error cannot be cleared B or regenerates consistently replace module ATDH Hose Unexpected Current Shorted If error cannot be cleared Hose or regenerates consistently replace module 333024 75 Troubleshooting Error A8DA A8DH CACM Hose No Current Hose Tripped circuit Visually check circuit Loose broken Check heater wiring for connection loose wires Heater A No Current A Tripped circuit Visually check circuit breaker breaker for a tripped condition Loose broken Check heater wiring for connection loose wires breaker breaker for a tripped MCM Communica Module does not Insert a system token into tion Error have software the ADM module and cycle the power Wait until the upload is complete
47. e Information Foam Resins with 245 fa Blowing Agents oome foam blowing agents will froth at temperatures above 90 F 33 C when not under pressure especially if agitated To reduce frothing minimize preheating in a circulation system Changing Materials NOTICE Changing the material types used in your equipment requires special attention to avoid equipment damage and downtime When changing materials flush the equipment multiple times to ensure it is thoroughly clean Always clean the fluid inlet strainers after flushing Check with your material manufacturer for chemical compatibility When changing between epoxies and urethanes or polyureas disassemble and clean all fluid components and change hoses Epoxies often have amines on the B hardener side Polyureas often have amines on the B resin side 333024 Models Models Reactor 2 E 30 and E 30 Elite All elite systems include fluid inlet pressure and temperature sensors Graco InSite and Xtreme Wrap 50 ft 15 m head hose For part numbers see Accessories page 11 E 30 Model E 30 Elite Model 10 kW 15 kW 10 kW 15kW Proportioner 2 2010 2 2011 2 2110 2 2111 Pressure psi MPa bar Cycle gal liter kg min Watts 10 30A 30 10 30 18 3O 30 18 30 30 Gun Part No 246102 246102 246102 246102 246702 246102 246102 246102 Gun Part No CSO2RD CSO2RD CSO2RD
48. e fluctuations that can damage electrical equipment and void the warranty 1 Flush if necessary See Flushing page 45 2 See Shutdown page 43 Flush Inlet Strainer Screen The inlet strainers filter out particles that can plug the pump inlet check valves Inspect the screens daily as part of the startup routine and clean as required Isocyanate can crystallize from moisture contamination or from freezing If the chemicals used are clean and proper storage transfer and operating procedures are followed there should be minimal contamination of the A side screen Note Clean the A side screen only during daily startup This minimizes moisture contamination by immediately flushing out any isocyanate residue at the start of dispensing operations 46 Close the fluid inlet valve on the y strainer inlet and shut off the appropriate feed pump This prevents material from being pumped while cleaning the screen Place a container under the strainer base to catch drain off when removing the strainer plug C Remove the screen A from the strainer manifold Thoroughly flush the screen with compatible solvent and shake it dry Inspect the screen No more than 25 of the mesh should be restricted If more than 25 of the mesh is blocked replace the screen Inspect the o ring B and replace as required Ensure the pipe plug D is screwed into the strainer plug C Install the strainer plug with the screen A and o
49. ealant to gauge Torque to 355 395 in Ibs 4044 6 Nem threads Apply sealant 113500 to threads Valve must be closed with handle position as Apply PTFE tape or thread sealant to tapered shown on drawing threads Apply grease on valve PE 80 333024 240844 Fluid Manifold Ref 401 402 402 4020 403 404 405 406 407 408 411 412 Part 255228 247824 158674 247779 102814 162453 15 669 247788 247789 112309 117556 121312 333024 Description MANIFOLD fluid KIT valve cartridge drain O RING BUNA N SEAL seat valve GAUGE press fluid FITTING 1 4 NPSM X 1 4 NPT SENSOR pressure fluid outlet HANDLE red HANDLE blue NUT hex jam NIPPLE 8 JIC x 1 2 NPT FITTING elbow 3 4 SAE x 1 2 JIC Qty N NNa a N gt 2 Ref 413 414 415A 416 419 Parts Part Description Qty 100840 FITTING elbow street 2 111457 O RING PTFE 2 189285 LABEL caution 1 150829 SPRING compression 2 117557 NIPPLE 10 JIC x 1 2 1 NPT Replacement Warning labels signs tags and cards are available at no cost Included in the following complete valve kits ISO Valve Kit left red handle 255149 Resin Valve Kit right blue handle 255150 Valve Set Kit both handles and grease gun 255146 87 Parts Electrical Enclosure 451 478 454 471 468 455 82 000000 asm polo
50. ed Check if the error follows the transducer Disconnect transducer cables from the MCM connectors 6 and 7 Reverse A and B connections and check if the errors follows If the error follows the transducer replace the pressure transducer Check to ensure the pressure transducer is properly installed and all wires are properly connected Check if the error follows the transducer Disconnect transducer cables from the MCM connectors 6 and 7 Reverse A and B connections and check if the errors follows If the error follows the transducer replace the pressure transducer If inlet sensors are not installed inlet sensors should be disabled on the oystem Setup screen Check to ensure inlet sensor is properly installed and all wires are properly connected Check if the error follows the inlet sensor Disconnect inlet sensor cables from the MCM connectors 8 and 9 Reverse A and B connections and check if the errors follows If the error follows the sensor replace the inlet sensor 333024 Troubleshooting 333024 Pressure Sensor Error Inlet B Pressure Imbalance A High Inlet sensors not installed Loose bad connection Bad sensor Pressure difference between A and B material is greater than the defined value Pressure imbalance is defined too low Out of material Fluid leaking from heater inlet rupture disk Feed system defective If inlet sensors are not
51. er B High Temperature B Bad RTD or bad owap A and B heater output RTD placement cables and RTD cables and against heater see if issue follows If so replace RTD Flow too high Use a smaller mix chamber for temperature that is rated for the unit in setpoint causing use temperature overshoots when gun is de triggered 333024 27 Troubleshooting T4DH Hose High Temperature Hose portion Hose exposed to an excessive heat source like hot sun or coiled hose can pass fluid more than 2 F 15 C over hose temperature setting to the FTS oetting the A or B setpoint much higher than hose setpoint can cause fluid more than 27 F 15 C over hose temperature setting to reach the FTS TAEA Heater A High Temperature Overtemperature owitch A switch sensed a fluid temperature above 230 11070 Disconnected or loose overtemperature switch cable connection Overtemperature switch failed in the open position 28 exposed hose from hot sun or expose FTS to same environment when at rest Uncoil entire hose before heating to avoid self heating Increase hose setpoint so it is closer to A and B setpoints Heater was delivered too much power causing the overtemperature switch to open RTD is not reading properly After the heater cools down replace RTD owitch closes and the error can be cleared when the heater temperature falls below 190 8770 If heater is not actually over tem
52. er ambient temperature 333024 Troubleshooting Erratic hose temperature Faulty FTS connections Verify that all FTS connections are snug and that pins of connectors are clean Unplug and re plug FTS wires along length of hose cleaning off any debris FTS not installed correctly FTS should be installed close to end of hose in same environment as gun Verify FTS installation see Repair Fluid Temperature Sensor FTS page 64 Hose does not heat FTS failed Check FTS see Repair Fluid Temperature Sensor FTS page 64 FTS not installed correctly FTS should be installed close to end of hose in same environment as gun Verify FTS installation see Repair Fluid Temperature oensor FTS page 64 Loose hose electrical connections Check connections Repair as necessary Circuit breakers tripped Reset breakers see Repair Circuit Breaker Module page 54 Hose zone not turned on Turn on hose heat zone A and B temperature setpoints too Check Increase if necessary low 38 333024 Troubleshooting Hoses near Reactor are warm but Shorted connection or failed hose With power off check the hose hoses downstream are cold heating element resistance with and without the whip hose attached With the whip hose attached the reading should be less than 3 ohm Without the whip hose attached the reading should be OL open loop See Check Hose Heat Connectors page 63 Low hose hea
53. error code 13 Troubleshooting Error Codes Note When an error occurs be sure to determine the code before resetting it If you forget which error code occurred see the Errors screen to view the last 200 errors with date time and description Low Motor Current L oose broken Check for loose wire connection terminations at MCM motor connector Bad Motor Disconnect motor output connector from MCM Confirm less than 8 ohms resistance between each pair of motor power leads M1 to M2 M1 to M3 M2 to M3 If any readings greater than 8 ohms check motor wiring for damage and or loose terminations High Current A Short circuit in Check wiring for touching Bad Heater Confirm resistance of heater Heater resistance should be 18 21 for each heater element 9 12 combined for 10 kW systems and 6 8 for 15 kW systems If out of tolerance replace heater element High Current B Short circuit in Check wiring for touching heater wiring wires Bad Heater Confirm resistance of heater Heater resistance should be 9 12 for 10 kW systems and 6 8 O for A4DB Heater B 15 kW systems If out of tolerance replace heater A4DH Hose High Current Hose Short circuit in Check continuity of hose wiring transformer windings Normal readings are about 0 20 on both primary and secondary If reading is 0 replace transformer Check for shorts between the primary winding and the support frame or enclosur
54. ers 114 1 Apply heavy duty extreme pressure grease liberally to washers 107 108 118 all gears Note and inside drive housing 102 If bearing housing 103 connecting rod 105 or pump 106 were removed reassemble rod in housing and install pump see Install Pump page 49 2 Install one bronze washer 108 in drive housing then install steel washers 107 118 as shown 3 Install second bronze washer 108 on gear cluster 104 and insert gear cluster in drive 5 Route cycle counter switch cable 121 around housing the motor fan and reattach to housing 102 with screws 122 Note 6 Install bearing housing 103 screws 113 and Drive housing crankshaft must be in line washers 114 Pumps must be in phase both at with crankshaft at other end of motor same position in stroke Install cover 60 and screws 21 8 Install motor shield 11 and screws 21 2N N 5N102 104 Figure 7 22 333024 Repair Electric Motor Removal NOTICE Be careful not to drop or damage the motor The motor is heavy and may require two people to lift Remove the system frame from the floor and L brackets 2 2 Remove drive housing and pump assemblies oee Repair Drive Housing page 50 3 Disconnect electric motor 101 power cable from
55. g to next step Shutdown system to avoid electric shock electrical wiring must be done by a qualified electrician and comply with all local codes and regulations To help prevent serious injury from pressurized fluid such as skin injection splashing 5 fluid and moving parts follow the Pressure Relief Procedure when you stop spraying and before cleaning checking or servicing equipment NOTICE Proper system setup startup and shutdown procedures are critical to electrical equipment reliability The following procedures ensure steady voltage Failure to follow these procedures will cause voltage fluctuations that can damage electrical equipment and void the warranty 1 Press to stop the pumps 06 21 11 10 43 Recipes E 30 Active 6 Turn off the air compressor air dryer and breathing air 7 Turn main power switch OFF ew 3 Relieve pressure See Pressure Relief Procedure page 42 To prevent electric shock do not remove any shrouds or open the electrical enclosure door 333024E 43 Shutdown 9 Engage gun piston safety lock then close fluid 8 Close all fluid supply valves inlet valves A and B f Probler Fusion TS TY gt bj Wy 73 AJ XS C M KC B L j 333024 44 Flushing To avoid fire and explosion Flush equipment only in
56. ing an RTD fixes the T6DT error replace the RTD 333024 Error T8DA T8DB T8DH V1CM 333024 E gt No Temperature Hise A No Temperature Rise No Temperature Rise Hose Low Voltage MCM Bad RTD or bad RTD placement against heater Bad heater rod or loose heater wire otarted spraying before heater reached operating temperature Bad RTD or bad RTD placement against heater Bad heater rod or loose heater wire otarted spraying before heater reached operating temperature otarted spraying before heater reached operating temperature Loose bad connection or tripped circuit breaker Low incoming line voltage Troubleshooting owap A and B heater output cables and RTD cables and see if issue follows If so replace RTD Confirm resistance of heater Heater resistance should be 9 12 O for 10 kW systems and 6 8 for 15 kW systems If out of tolerance check for loose heater rod wire s wires or replace heater rod if necessary Wait until operating temperature has been reached before spraying or recirculating owap A and B heater output cables and RTD cables and see if issue follows If so replace RTD Confirm resistance of heater Heater resistance should be 9 12 O for 10 kW systems and 6 8 O for 15 kW systems out of tolerance check for loose heater rod wire s wires or rep
57. into pail Do not use pail liners unless they are antistatic or conductive Stop operation immediately if static sparking occurs or you feel a shock Do not use equipment until you identify and correct the problem Keep a working fire extinguisher in the work area THERMAL EXPANSION HAZARD Fluids subjected to heat in confined spaces including hoses can create a rapid rise in pressure due to the thermal expansion Over pressurization can result in equipment rupture and serious injury Open a valve to relieve the fluid expansion during heating Replace hoses proactively at regular intervals based on your operating conditions 333024 333024 Warnings PRESSURIZED ALUMINUM PARTS HAZARD Use of fluids that are incompatible with aluminum in pressurized equipment can cause serious chemical reaction and equipment rupture Failure to follow this warning can result in death serious injury or property damage Do not use 1 1 1 trichloroethane methylene chloride other halogenated hydrocarbon solvents or fluids containing such solvents e Many other fluids may contain chemicals that can react with aluminum Contact your material supplier for compatibility PLASTIC PARTS CLEANING SOLVENT HAZARD Many solvents can degrade plastic parts and cause them to fail which could cause serious injury or property damage Use only compatible water based solvents to clean plastic structural or pressure containing parts See Technic
58. isconnect tubes T Remove both tube fittings U from wet cup Loosen locknut by hitting firmly with a non sparking hammer Unscrew pump far enough to expose rod retaining pin Push retaining wire clip up Push pin out Continue unscrewing pump 55 n 5 SONS A b gt ti22819a Pump A Figure 3 Flat side faces up gt Lubricate threads with ISO oil or grease P3 Pump top threads must be nearly flush with bearing face N Note oteps 12 and 13 apply to pump B 12 Disconnect fluid inlet C and outlet D Also disconnect steel outlet tube from heater inlet 13 Push retaining wire clip E up Push pin F out Loosen locknut by hitting firmly with a non sparking hammer Unscrew pump 333024 Repair ti22820a Flat side faces up PN Lubricate threads with ISO oil or grease N Pump top threads must be nearly flush with bearing face N Install Pump Note oteps 1 5 apply to pump B To pump A proceed to step 6 Ensure locknut G is screwed on pump with flat side up Screw pump into bearing housing M until pin holes align Push pin F in Pull retaining wire clip E down See Fig 4 for view and assembly notes Continue screwing pump into housing until fluid outlet D is aligned with steel tube and top threads 1 16 in 2 of bearing face N
59. ized Graco distributor for verification of the claimed defect If the claimed defect is verified Graco will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE Graco s sole obligation and buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty hereunder must be brought within the latter of two 2 years of the date of sale or one 1 year the warranty period expires GRACO MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANT ABILITY AND FITNESS FOR A PARTICULAR PURPOSE IN CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY GRACO These items sold but not manufactured by Graco such as electric motors switches hose etc are subject t
60. lace heater rod if necessary Wait until operating temperature has been reached before spraying or recirculating Wait until operating temperature has been reached before spraying or recirculating Check wiring for loose connection or tripped circuit breaker Measure voltage at circuit breaker and ensure voltage is greater than 195 VAC 31 Troubleshooting Error 2 V2MA V2MB V2MH V3IT V3MA Type E Ji Low Voltage CAN Bad 24 VDC power Check voltage of power supply supply Voltage should be 23 25 VDC If out of tolerance replace power supply Low Voltage CAN Bad 24 VDC power Check voltage of power supply supply Voltage should be 23 25 VDC If out of tolerance replace power supply Low Voltage A Loose connection Check wiring for loose or tripped circuit connection or tripped circuit breaker breaker Low incoming line Measure voltage at circuit voltage breaker and ensure voltage is greater than 195 VAC Low Voltage B Loose connection Check wiring for loose or tripped circuit connection or tripped circuit breaker breaker Low incoming line Measure voltage at circuit voltage breaker and ensure voltage is greater than 195 VAC Low Voltage Hose Loose connection Check wiring for loose or tripped circuit connection or tripped circuit breaker breaker Low incoming line Measure voltage at circuit voltage breaker and ensure voltage is greater than 195
61. me o 1 7 7 gt 24U840 TUBE b side outlet 1 10kw rus esae me 240833 ese me 1 esae oe 1 1 15K742 TRANSFORMER 4090va 230 90 19 125643 FITTING elbow 3 8 npt 2 2 2 2 2 2 8 20 119865 SCREW mch hex serrated 3 8 in x 1 4 20 333024 71 Parts Ref Part Description Quantity 272010 272011 272012 272110 272111 272112 21 118444 SCREW mch slot hex 12 12 12 12 12 12 wash hd 1 2 in 10 24 22 117683 SCREW mch phil pan hd 1 5 in x 26 32 23 113796 SCREW flanged hex hd 11 13 13 11 13 13 3 4 in x 1 4 20 25 111800 SCREW cap hex hd 4 4 4 4 4 4 7 32 in x 5 16 18 28 104859 SCREW tapping pnhd 2 2 2 2 2 2 5 16 in x 210 16 o oos 2 2 240847 FAN cooling 120mm 24vdc 24R685 ENCLOSURE lower dinrail includes 33a 33d 24U849 KIT module din rail heater see Heater and Transformer Terminal Block Module page 85 19 6 7 INSULATOR Foam sa nass rre 1 mme washer nt 4 wwe crower 2 2 2 2 2 2 m qnem ro sr wes nene 4 4 3 5 spes e
62. min l min 94 333024 Table 3 Fusion Mechanical Purge Round Pattern 3500 241 24 1 3000 207 20 7 XR2323 RTM040 2500 174 17 4 XR2929 040 PRESSURE iis 138 13 8 i MR3535 psi bar 040 1500 MR4747 103 10 3 55 XR3535 1000 55 XR4747 69 6 9 RTM055 500 35 3 5 FLOW gal min l min Table 4 Fusion Mechanical Purge Flat Pattern 3500 241 24 1 XF2323 3000 424 207 20 7 2929 2500 424 174 17 4 2929 424 PRESSURE 2000 138 13 8 psi bar XF1818 ied 1500 424 MF3535 ullus FTM638 103 10 3 XF5757 XF3535 FTM638 1000 FTM638 69 6 9 500 35 3 5 0 2 0 4 0 6 0 8 1 1 2 1 4 1 6 0 7 1 5 2 3 3 0 3 8 4 5 5 3 6 0 FLOW gal min l min 333024 1 8 6 8 Performance Charts 2 0 7 6 95 Technical Specifications Technical Specifications Reactor 2 E 30 and E XP2 Proportioning System Meis Maximum Fluid Working Pressure E 30 2000 psi 14 MPa 140 bar E XP2 3500 psi 24 1 MPa 241 bar Maximum Fluid Temperature E 30 88 C EXP2 88 Maximum Flow Rate E 30 13 5 EXP2 7 6 ipm Maximum Heated Hose Length Length 310 ft 94 m Output per Cycle ISO and RES E 30 0 0272 gal 0 1034 liter E XP2 0 0203 gal 0 0771 liter Operating Ambient Temperature Range Temperature 20 to 120 7 to 49 Line Voltage
63. mp 10 Remove screw 20 and lower din rail cover 48 4 Press to park the pumps in the down position The park operation is complete when green dot goes out Verify the park operation is complete a A Side Disconnect A side heater wires before moving to next step transformer and transformer fan wires from lower din rail 33 11 Disconnect heater wires b B Side Disconnect B side heater wires and remove lower din rail 33 from B side heater 5 12 Test heater wires with ohmmeter 5 Total Element Heater Wattage 30 10 10 200 2 550 18 21 per kw element 6 15 300 2 550 18 21 per element NOTICE To prevent a short circuit or lowering the transformer life do not splash fluid on transformer Cover transformer with a plastic sheet or piece of cardboard 7 Relieve pressure See Pressure Relief Procedure page 42 333024 29 Repair 13 14 15 16 17 18 19 Remove nuts 27 and transformer cover 8 Cover transformer with plastic sheet or cardboard Disconnect overtemperature switches 209 from cable Loosen ferrule nut N Remove RTD 212 from heater housing Do not remove adapter 206 unless necessary If adapter must be removed ensure that mixer 210 is out of the way when replacing adapter Disconnect inlet and outlet fluid tubes from heater Remove two bolts 23 and lift heater over transformer Place heater block 201 in
64. o Electrical Schematics page 89 and circuit breaker table Follow Shutdown instructions See Shutdown page 43 Refer to circuit breaker identification table and electrical diagrams in Reactor repair manual Loosen two screws connecting wires and bus bar to circuit breaker that will be replaced Disconnect wires Pull locking tab out 1 4 in 6mm and pull circuit breaker away from the din rail Install new circuit breaker Insert wires and tighten down all screws ti22853a Sees eee RES mE REA mE RET RESTATE Sr N 03 C04 0805 Figure 8 Circuit Breakers Circuit Breakers CB01 Heated Hose CB02 20A Motor Control Module MCM CB03 ISO Heater CB04 RES Heater 05 Hose Heat Transformer 333024 Replace Fluid Inlet Sensor Note For Elite models only Perform Shutdown page 43 Perform Pressure Relief Procedure page 42 Disconnect inlet sensor cable from the fluid inlet assembly Inspect cable for damage and replace if necessary See Electrical Schematics page 89 Figure9 Fluid Inlet Sensor To replace sensor cable a Open wire bundle and remove sensor cable b Cutany wire ties and disconnect from MCM Electrical Schematics page 89 NOTICE To prevent damage to cable route and secure cable in wire bundle with wire ties 333024 5 Repair Replace sensor 602
65. o the warranty if any of ee Graco will provide purchaser with reasonable assistance in making any claim for breach of ese warranties In no event will Graco be liable for indirect incidental special or consequential damages resulting from Graco supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of Graco or otherwise FOR GRACO CANADA CUSTOMERS The Parties acknowledge that they have required that the present document as well as all documents notices and legal proceedings entered into given or instituted pursuant hereto or relating directly or indirectly hereto be drawn up in English Les parties reconnaissent avoir convenu que la r daction du pr sente document sera en Anglais ainsi que tous documents avis et proc dures judiciaires ex cut s donn s ou intent s la suite de ou en rapport directement ou indirectement avec les proc dures concern es Graco Information For the latest information about Graco products visit www graco com To place an order contact your Graco Distributor or call to identify the nearest distributor Phone 612 623 6921 or Toll Free 1 800 328 0211 Fax 612 378 3505 All written and visual data contained in this document reflects the latest product information available at the time of publication Graco reserves the right to make changes at any time without noti
66. off 333024 7 Perform Pressure Relief Procedure page 42 8 Remove the system frame from the floor and L brackets 9 Remove two bolts and nuts and fold the electrical enclosure backward 10 Remove screws 21 and motor shroud 11 Rest the motor shroud behind the motor without straining the fan power cable Note Examine bearing housing 103 and connecting rod 105 If these parts need replacing first remove the pump 106 see Remove Pump page 48 11 Remove cover 60 and screws 21 12 Remove cycle counter 121 from housing by removing screw 122 13 Disconnect pump inlet and outlet lines Remove screws 113 washers 115 and bearing housing 103 333024 Repair NOTICE Do not drop gear cluster 104 when removing drive housing 102 Gear cluster may stay engaged in motor front end bell or drive housing 14 Remove screws 112 119 and washers 114 and pull drive housing 102 off motor 101 Note The A side drive housing includes cycle counter switch 121 If replacing this housing remove screws 122 and switch Reinstall screws and switch on new drive housing ti22823a Figure 6 27 Repair Installation 4 Push drive housing 102 onto motor 101 Install screws 112 and wash
67. ose heats but heats slower Ambient temperature is too cold Relocate hoses to a warmer area than usual or it does not reach or recirculate heated fluid through temperature the hose FTS failed or not installed correctly Check FTS see Check RTD Cables and FTS page 63 Low supply voltage Verify line voltage Low line voltage significantly reduces power available to the hose heat system affecting longer hose lengths Hose does not maintain A and B setpoints too low Increase A and B setpoints temperature while spraying Hose is designed to maintain temperature not to increase it Ambient temperature is too cold Increase A and B setpoints to increase fluid temperature and keep it steady Flow too high Use smaller mix chamber Decrease pressure Hose was not fully preheated Wait for hose to heat to correct temperature before spraying Low supply voltage Verify line voltage Low line voltage significantly reduces power available to the hose heat system affecting longer hose lengths Hose temperature exceeds A and or B heaters are overheating Check primary heaters for either setpoint material a RTD problem or a failed element attached to RTD see Electrical Schematics page 89 Faulty FTS connections Verify that all FTS connections are snug and that pins of connectors are clean Unplug and re plug RTD wires cleaning off any debris Ambient temperature is too high Cover hoses or move to a location with a low
68. perature check all wiring and connections between the TCM and the overtemperature switches Replace overtemperature switch 333024 Troubleshooting 333024 High Temperature owitch B High Temperature Motor Overtemperature switch sensed a fluid temperature above 230 110 Disconnected or loose overtemperature switch cable connection Overtemperature switch failed in the open position Cooling fan is not operating properly Disconnected or loose motor temperature cable High ambient temperature Disconnected or loose RTD cable or connection Bad RTD Heater was delivered too much power causing the overtemperature switch to open RTD is not reading properly After the heater cools down replace RTD owitch closes and the error can be cleared when the heater temperature falls below 190 F 8770 If heater is not actually over temperature check all wiring and connections between the TCM and the overtemperature switches Replace overtemperature switch Check to see that the motor fan is moving Measure voltage to fan There should be 24 VDC If no voltage is measured check fan wiring If the fan has voltage but is not moving replace fan If necessary use an air hose to blow out around the fan housings and remove any built up debris Verify wiring between the motor temperature sensor and the MCM Ensure ambient temperature is below 120 F 48
69. r WMIO operating has occurred fan inside the module is not working properly Check TCM fan for debris and clear with forced air if necessary T3NM MCM MCM Cutback Motor is operating The system is running at a outside of the lower setpoint to preserve pressure flow motor life Run the system curve at a lower duty cycle or with a smaller mix chamber MCM High Temperature High ambient Ensure ambient MCM temperature temperature is below 120 F 48 C before using the system Enclosure fan not Ensure fan in electrical operating enclosure is spinning If it is not check fan wiring or replace fan 26 333024 Troubleshooting TACT TCM High Temperature High ambient Ensure ambient TCM temperature temperature is below 120 F 48 C before using the system Enclosure fan not Ensure fan in electrical operating enclosure is spinning If it is not check fan wiring or replace fan Module fan not If a TCM fan error WMIO operating has occurred fan inside the module is not working properly Check TCM fan for debris and clear with forced air if necessary TADA Heater A High Temperature Bad RTD or bad owap A and B heater output RTD placement cables and RTD cables and against heater see if issue follows If so replace RTD Flow too high Use a smaller mix chamber for temperature that is rated for the unit in setpoint causing use temperature overshoots when gun is de triggered TADB Heat
70. raco warrants all equipment referenced in this document which is manufactured by Graco and iue its name to be free from defects in material and workmanship on the date of sale to the original purchaser for use With the exception of any special extended or limited warranty published by Graco Graco will for a period of twelve months from the date of sale repair or replace any part of the equipment determined by Graco to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with Graco s written recommendations Graco Part Number Warranty Period 24U050 Electric Motor 36 Months or 3 Million Cycles 24U051 24U831 Motor Control Module 36 Months or 3 Million Cycles This warranty does not cover and Graco shall not be liable for general wear and tear or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non Graco component parts Nor shall Graco be liable for malfunction damage or wear caused by the incompatibility of Graco equipment with structures accessories equipment or materials not supplied by Graco or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by Graco This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an author
71. rmocouple is not oee RTD or Thermocouple repair displayed on website correctly installed on the hose section is broken Pressure data not displayed on Reactor pressure measurement is See System troubleshooting website not working section 333024 41 Pressure Relief Procedure Pr re Reli f Pr r 4 Route fluid to waste containers or supply tanks essure ele ocedu e Turn PRESSURE RELIEF SPRAY valves SA SB to PRESSURE RELIEF CIRCULATION Follow the Pressure Relief Procedure 1 whenever you see this symbol 22 Ensure gauges drop to 0 GA GB gt 5 790 This equipment stays pressurized until pressure aul is manually relieved To help prevent serious injury from pressurized fluid such as skin injection splashing fluid and moving parts follow the 5 Pressure Relief Procedure when you stop spraying and before cleaning checking or servicing equipment The Fusion AP gun is shown 1 Relieve pressure in gun and perform gun shutdown procedure See gun manual 6 Disconnect air line and remove gun fluid 2 Close gun fluid inlet valves A and B manifold 3 Shut off feed pumps and agitator if used 42 333024 Shutdown Shutdown 4 Press to park the Component A Pump The park operation is complete when green dot goes out Verify the park operation is complete before movin
72. see o fre eromen 16X095 CONNECTOR power male 4 pin __ 3 INIS INIS INIS INIS INIS INIS Ah Jh 2 333024 Parts Part Description Quantity 272010 272011 272012 272110 272111 272112 4 44 24 725 BRIDGE plug in jumper 4 4 ut35 45 106569 electrical 1 460 247242 CABLE over temp 10 1 NN D 24P970 CABLE over temp 15 kW IURE 104765 PLUG pipe headless pipe headless 16V268 COVER top dinrail 15Y118 LABEL made in the USA 24V150 PROPORTIONER module E 30 see Proportioner Module page 76 24V151 PROPORTIONER module E XP2 see Proportioner Module page 76 kW Reactor 2 24U321 KIT asm pair elite reactor see Fluid Inlet Kits page 87 mM 240320 KIT assembly pair 1 1 1 std reactor see Fluid Inlet Kits page 87 5209 16X118 MODULE cellular gps 1 1 1 temp 530 24 050 CABLE m8 4p f to m12 1 1 1 8p m 1 5m 16W130 CABLE m12 5p fem male 2 0m 24U845 TUBE pressure relief 191892 FITTING elbow street EN EN EN ES 90 deg 1 8 npt 116746 FITTING barbed plated 1 8 27 npt x 1 4 in hose I D 58 16W218 LABEL branding e 30 16W321 LABEL branding e 30 elite 16W215 LABEL branding e xp2 16W322 LABEL
73. t A and B temperature setpoints too Increase A and B setpoints Hose low designed to maintain temperature not increase temperature Hose temperature setpoint too Check Increase if necessary to low maintain heat Flow too high Use smaller mix chamber Decrease pressure Low current FTS not installed Install FTS see operation manual Hose heat zone not turned on long Allow hose to heat up or preheat enough to reach setpoint fluid Loose hose electrical connections Check connections Repair as necessary Ambient temperature is to low Relocate hoses to a warmer area or increase A and B setpoints 333024E 39 Troubleshooting Primary Heater Before performing any troubleshooting procedures 1 Relieve Pressure See Pressure Relief Procedure page 42 2 Turn main power switch OFF 3 Allow equipment to cool Problems Try the recommended solutions in the order given for each problem to avoid unnecessary repairs Also determine that all circuit breakers switches and controls are properly set and wiring is correct before assuming there is a problem Control of primary heat is Dirty RTD connections Examine RTD cables connected abnormal high temperature to TCMs Confirm RTDs are overshoots 4 occurs not plugged into opposite heat intermittently zone Unplug and re plug RTD connectors Unplug and re plug RTD connectors Ensure RTD tip contacts the heater element RTD not contacting hea
74. ter Loosen ferrule nut push in RTD element so tip contacts heater element Holding RTD tip against heater element tighten ferrule nut 1 4 turn past tight Failed heater element see Replace Heater Element page 59 Signal failure from RTD see T6DA T6DB Error Codes 40 333024 Troubleshooting Graco InSite No module status LEDs are No power to cellular module Turn Reactor ON illuminated Ensure unit is properly installed Verify 24V at output of the power supply Make sure the M8 4 pin to M12 8 pin cable is installed between cellular module and power supply green module status LED identify the location flashing Unable to identify location In a location where GPS lock cannot clear view of the sky occur Buildings and warehouses Use extension cable 16X521 and often prevent GPS locks move cellular module to a location with a clear view of the sky connection orange module status connection establish the connection LED flashing Unable to establish cellular Move system to a location with connection cellular service to establish cellular connection Use extension cable 16X521 and move cellular module to a location with a clear view of the sky Cannot view data for my unit s on Graco InSite unit has not been Activate unit See Registering website activated and Activating the Graco InSite section on website measurement is not working section Hose zone temperature data not The RTD or the
75. too large for set pressure Line frequency is below 45 Hz Line frequency is below 45 Hz Line frequency is below 45 Hz Line frequency is above 65 Hz Line frequency is above 65 Hz Line frequency is above 65 Hz Motor will not rotate Damaged gear train Chemical pump is stuck Manual Hose Mode Install a functioning fluid temperature sensor FTS on the hose Manual hose mode will automatically turn off Do not remove USB drive until download upload is complete Enable USB download up loads on the Advanced Setup screen before insert ing a USB drive Reference the pressure flow curves and select a tip size that is the correct size for the set pressure Ensure line frequency of incoming power is between 45 and 65 Hz Ensure line frequency of incoming power is between 45 and 65 Hz Ensure line frequency of incoming power is between 45 and 65 Hz Ensure line frequency of incoming power is between 45 and 65 Hz Ensure line frequency of incoming power is between 45 and 65 Hz Ensure line frequency of incoming power is between 45 and 65 Hz Remove pump gear housings from motor and check that motor shaft rotates freely in direction indicated on motor housing Check motor pump gear trains for damage and repair or replace as necessary Repair or replace chemical pump 333024 Error L1AX L1BX MMUX POAX 333024 Troubleshooting Low Chemical
76. transformer wires in terminal blocks 1 Check wires and transformer TB17 and TB18 there should be continuity See Shutdown page 43 c Close the circuit breaker Shut off 05 56 MEUS c Use ohmmeter to test for continuity ee between terminals 2 and 4 of CBO5 If there is no continuity check transformer Epp DT 2 Check transformer SS el 122852 a See Shutdown page 43 Fi 17 b Remove lower shroud gure c Locate the two smaller 10 AWG wires d Apply incoming power to system labeled 1 and 2 coming out of transformer e To verify voltage on the secondary leads Trace these wires back to terminal blocks of the transformer measure between the TB15 and TB16 terminals terminals 3 and 4 on 17 and d Use an ohmmeter to test for continuity 1818 Verify voltage is approximately 90 between two wires there should be for 240 input continuity f See the Diagnostic Run Screen on the ADM The Diagnostic Run Screen displays Transformer Secondary Check the incoming 90 Vac to the TCM Hose See Electrical Schematics page 89 Voltage The diagnostic screen will show if the circuit breaker has been tripped for the 1 Check wires and transformer incoming power to the TCM Disconnect 7 pin green connector from TCM 12120113 08 00 r b Use an ohmmeter to test for continuity E 30 Active No Active Errors between terminals 6 and 7 on the TCM pin A Chemical
77. ure each CAN cable connection is tight Verify the power supply is outputting 24 VDC If not check power supply wiring If wiring is okay replace the power supply Check the CAN cables running between GCA modules and tighten of needed If the problem still persists move each cable around the connector and watch the flashing yellow light on the GCA modules If the yellow light stops flashing replace the CAN cable Mix chamber too large for system selected Use mix chamber rated for system Ensure the system has chemical and the feed pumps are operating correctly No material in pumps Verify pumps are supplying chemical necessary replace or refill drums Check wiring between cycle switch and MCM Check presence and position of cycle switch magnet on output crank arm 7 Troubleshooting Error EVCH ADM EAUX EVUX F9DX H2MA H2MB H2MH Hose H3MA H3MB H3MH Hose K8NM lt 78 Location Heater A Heater B Heater A Heater B gt gt 2 Enabled USB Busy USB disabled High Pressure Flow Cutback Low Frequency A Low Frequency B Low Frequency Hose High Frequency A High Frequency B High Frequency Hose Locked Rotor Motor Manual hose mode has been enabled in System Setup screen USB drive has been inserted to the ADM USB download uploads are disabled Mix chamber is
78. ut cables and RTD cables and see if issue follows If so replace RTD Confirm resistance of heater Heater resistance should be 9 12 O for 10 kW systems and 6 8 O for 15 kW systems If out of tolerance check for loose heater rod wire s wires or replace heater rod if necessary Use a smaller mix chamber that is rated for the unit in use If recirculating decrease flow or decrease temperature setpoint Recirculate heated chemical back to drum in cold conditions before startup Recirculate fluid through heaters until inlet fluid temperature is above defined error level Increase the low temperature deviation level on the System Setup screen Recirculate fluid through heaters until inlet fluid temperature is above defined error level Increase the low temperature deviation level on the System Setup screen 25 Troubleshooting T3CH Hose Hose Cutback Hose current has Hose setpoint higher than A been reduced and B setpoints Decrease because hose hose setpoint Hose FTS is in a colder environment than the rest PENOU of the hose Expose FTS to the same environment as the rest of the hose T3CT TCM TCM Cutback High ambient Ensure ambient temperature temperature is below 120 F 48 C before using the system Enclosure fan not Ensure fan in electrical operating enclosure is spinning If it is not check fan wiring or replace fan Module fan not If a TCM fan erro
79. with a system or sold 121006 190 ft 45 m CAN cable for remote individually are not approved by Intertek display module 24N365 RTD Test Cables to aide resistance measurements 333024 77 Supplied Manuals Supplied Manuals The following manuals are shipped with the Reactor 2 Refer to these manuals for detailed equipment information Manuals are also available at www graco com Manus Desi 333023 Reactor 2 E 30 and E XP2 Operation Quick Guide Shutdown Quick Guide Related Manuals The following manuals are for accessories used with the Reactor Component Manuals in English Manuals are available at www graco com System Manuals 333023 Reactor 2 E 30 and E XP2 Operation Displacement Pump Manual 309577 Electric Reactor Displacement Pump Repair Parts Feed System Manuals 309572 Heated Hose Instructions Parts 309852 Circulation and Return Tube Kit Instructions Parts 309815 Feed Pump Kits Instructions Parts 309827 Feed Pump Air Supply Kit Instructions Parts Spray Gun Manuals Fusion AP Gun 312666 Fusion CS Gun 313213 Probler P2 Gun Accessory Manuals 3A1905 Feed Pump Shutdown Kit Instructions Parts 3A1906 Light Tower Kit Instructions Parts Remote Display Module Kit Instructions Parts 332735 Air Manifold Kit Instructions Parts 332736 Handle and Wheel Kit Instructions Parts 333276 Graco InSite M Kit Instructions Parts 12 333024 Troubleshooting

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